Leak at Top of Injector
 

Just finished up putting in my new Monark nozzles in my 240D, and really like them. However, I have one slight leak, and it is coming from the connection at the top, where the injector lines mates to the injector. So it looks like the mating surfaces must not be perfectly made, and I have already applied some good force, but leak is still there.

So... questions:
-Is there a way to stop it by possibly smoothing out the mating surfaces, maybe with some grit paper?
-If I need a new injector line, where do you get one, and do they come pre-bent, or are they custom-fit?
-I thought about swapping two injectors to see if this might cure it, and to ID whether it is the line that is bad or the top fitting on the injector. Every time I pull the injector do I need a new heat shield? Do they act like a crush washer and cannot be re-used? They are brand new, just got put in, and hate to have to put in a new one each time I unscrew the injector.

Always appreciate the help!

[QUOTE=treiberg;2454120]Just finished up putting in my new Monark nozzles in my 240D, and really like them. However, I have one slight leak, and it is coming from the connection at the top, where the injector lines mates to the injector. So it looks like the mating surfaces must not be perfectly made, and I have already applied some good force, but leak is still there.


-Is there a way to stop it by possibly smoothing out the mating surfaces, maybe with some grit paper?
There is a yes and no to this. I have done this before on the Injector but I had a cone shaped Mandrel and used lapping compound. If the Cone on the Fuel Injection line is damaged it has to be replaced.
I did this one time. I got a tiny Copper Washer and put that into the top of the Injector and tightened the Fuel Injection Line over that. It only works if you can keep it centered.

-If I need a new injector line, where do you get one, and do they come pre-bent, or are they custom-fit? The Dealer may have new ones, Junkyards Have used ones ($5 each in my area). Some large Fuel Injcection Shops can make them but they come straight; but the new tubing is easier to bend than the old tubeing.

-I thought about swapping two injectors to see if this might cure it, and to ID whether it is the line that is bad or the top fitting on the injector. Every time I pull the injector do I need a new heat shield? yes, you are supposed to.
(I get them online when I buy enough parts to get the free shipping and the last time I bought them they were arund $1.10.)

Do they act like a crush washer and cannot be re-used? Yes.

They are brand new, just got put in, and hate to have to put in a new one each time I unscrew the injector.

I will say this my Volvo Diesel uses the same Injector Heat Shields and the same sized Injectors. When I rebuilt my Injectors and re-installed them I did not know the Heat Shields needed changing. I drove over 1.5 years like that with no problems until I had to pull the head for another reason and the Heat Shields came with the Headgasket Kit and I realized they were supposed to be changed.
So nothing awful is going to happen if you reuse the Heat Shields. If it was my car I would go ahead and get your Car Running. Find some place that sells the Heat Shields cheap and buy them and some extras when you order things like Oil and Transmission filters. And I would change them when I got the new Heat Shields.
It is better to have invested $6-$10 and keep some heat shields on hand ahead of time than it is to pay $3 or more each for them when you absoutely have to have them.

I would also buy at leas 1 extra as if you drop one they like to roll.

Thanks Diesel911, you always have great ideas, and you take the time to explain them. I'll report back later.